Q&A

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Rules for sword building? of course! what type of sword do you need?

a MW greatsword(halfing sized)? At 1/3 cost, that would be 116gp 6sp 7cp

Just need to figure up crafting time, but it's perfectly doable.

Taking 10, A little under five weeks of work according to RAW. I think.

....Wait!
5 weeks if using the reduced price to calculate the progress. If it is supposed to use the full price... ~15 weeks.

aaand the DC goes up, so she couldn't take 10.

Stupid rules. Nevermind.

Doing some calculations I get:

Brunhilde's base craft weaponsmithing is: 1 rank + 2 ability + 3 trained + 2 craftswoman = +8
That plus Greg's assisting giving a +2 is +10 total

Greatsword = 50gp = 500sp @ DC15, going to accelerated craft gives DC25

Taking 20, Brun aided makes progress of CHECK30 * DC25 = 750sp per week, so the basic halfling sized Greatsword is ready in little less than 5 days.

The MWK part (which is calculated separately) is 300gp = 3000sp @ DC20, going to accelerated craft gives DC30

Taking 20 Brun aided makes progress of CHECK30 * DC30 = 900sp per week, so making the greatsword MWK takes Brunhilde 3 1/3 weeks of work. Four weeks total, not bad for having only one rank . Also she gets a 5% additional cost reduction for working on metal parts.

Alrighty. Well in that case, I'd like to commission a tiny big sword.

Question: How do you want to rule "Multitalented" the Half-Elf racial feature?

It does funny stuff to Gestalt. Since I can take two favored classes, and each level gain two of the bonuses..
Possible solutions: Make it so you can't take the same Favored Class bonus more then once at each level (no 2hp/lvl, but 1hp+1skill rank is ok)

Question 2: Can a Half-Elf take the Spire Defender Alternate class for the Magus? (RAW it is reserved for Elves, but requires DM approval for other races)

The possible solution for No 1 sounds fair. For No 2 I see no problem with a half elf taking an elf flavored class, go ahead.